Bringing production closer to its manufacturing site was a key rationale for Trend Control Systems , part of the Honeywell Group of companies .
For over five years , Trend ’ s climate control components - supplied to high-end hotels and commercial office buildings - are moulded , finished and part-assembled by Broanmain . Made to order and dispatched to Trend at least twice a week , the Trend team relies emphatically on a simple yet effective Kanban lean manufacturing technique to control stock levels .
Real time quality control Another benefit of shorter runs and local production is increased quality and quicker reactions if they require a customisation . Operations Manager Thomas Catinat comments : “ If there ’ s an issue with the component or consumer trends dictate a change , customers can call us , or even visit us on site . Our in-house tooling engineers can amend the component and run off a new batch , dispatching it within 24-hours . Waste is kept to a minimum and production schedules are tightly maintained .”
Broanmain ’ s involvement from the start of the toolmaking design process pays dividends further down the line , too . “ Toolmakers have a complementary knowledge to moulders . When this expertise is combined together from the start of a project , every aspect of the design , moulding and finishing processes can be factored in . Including the materials the components will be made from , to the machine they will be
moulded on . Each stage and element plays a critical role in manufacturing the perfect component from the first shot onwards ,” explains Thomas .
Reinvention for resilience For 20 + years , the low cost offshoring model worked for many OEMs . Whilst lower wage and raw material costs were the initial attraction , many of these topline benefits have eroded ; superseded by delivery on demand . In comparison to the off-shoring wave , it ’ s now evident that OEMs are no longer influenced on price and labour costs alone . Production skills , capacity , and the space to hold inventory are all equally important factors to consider when looking to derisk supply chains .
Academics suggest that rightshoring – blending offshoring and reshoring - offers a balanced mix to achieve the optimum level of manufacturing efficiencies and productivity . By definition , rightshoring seems to be the obvious ‘ catch all ’ solution . However , manufacturing businesses evolve constantly . What ’ s the right choice for one , may not work for another . Likewise , what ’ s right for an OEM in 2023 , may need rejigging again several years down the line .
Uncovering the right sourcing strategy can be fraught with risks . As Cucumber ’ s Product Manager corroborates , expert industry knowledge should never be underestimated . It also depends on other factors such as where the best skills are located . “ For an OEM like ourselves , onshoring every aspect might not be the most prudent , productive or cost efficient move ,” claims John . “ It ’ s critical to weigh up all the hidden costs , including managing the relationships with suppliers , order turnaround times , quality , wage inflation , export tariffs and even the volatility of exchange rates .”
Broanmain ’ s Managing Director Jo Davis concurs , summing up : “ Just as OEMs need access to diverse skillsets , lessening over-reliance on a single import source can be sensible . For components that require a high level of innovation , close proximity to the manufacturer clearly reduces the logistical and quality management challenges . Yet , the intrinsic value of being able to diversify supply chains and leverage a hybrid rightshoring strategy which can flex and be controlled within the UK creates an inviting environment that drives future operational excellence .”
Having supported a number of customers to bring technical moulding projects closer to home , Jo advises OEMs to initially focus on where production capacity in the UK can be expanded . “ In time you might gradually move the entire supply chain . Inevitably , taking a more considered approach builds confidence and ensures that quality is not compromised during the transition ,” adds Jo .
According to Make UK ’ s The Facts annual analysis , domestic manufacturing continues to thrive , accounting for £ 183bn in output . In 2022 , the UK retained its rank as the ninth largest manufacturing nation in the world .
www . broanmainplastics . co . uk
About Broanmain
Factoring in moulding parameters is essential in the tool design process , which Broanmain can oversee entirely from its UK toolshop
Broanmain Plastics is a specialist family-owned technical trade plastic moulder and one of only a few UK plastic moulders to offer thermoplastic , thermosetting and injection moulding from one facility .
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